United States Stove 1602G Furnace User Manual
Contents
1. FIREBRICK AND BAFFLE REPLACEMENT FIREBOX BRICK REPLACEMENT This furnace comes from the factory with the firebrick in stalled However if brick replacement is necessary follow these instructions Before furnace operation remove the brick retaining strip This piece is used during shipping to reduce brick damage For model 1602 there are 6 full brick and 1 half brick per side Install the half brick first by putting the bottom of the brick in first and let it rest against the firebox side and fire grates Then slide it to the rear After that install the 2 3 4 5 amp 6 brick sliding the 6th brick forward to allow for the 7th brick Repeat for opposite side For model 1802 there are 8 full brick and 1 half brick per side Install the brick in the same manner as previously in structed for the model 1602 NOTE Prior to operation be sure to remove the brick retaining strips BRICK RETAINING STRIP BAFFLE BRICK REPLACEMENT If baffle replacement is necessary slide the baffie out until you can access the nuts thru the flue outlet Once the nuts have been removed slide the baffle off the rod and thru the opening in the firebrick You may have to remove one of the firebrick to make baffle removal easier For model 1602 there are 4 full brick and 1 half brick in the top of the furnace Install the brick by inserting one end of the brick angled upward and th2. USSC 12 PARTS DIAGRAM AND LIST Feed Door Assy w Rope Gasket 69091 Door Handle 24179 Lock Nut 1 2 13 83444 N S aeron OOS Shaker Handle 69005 Bracket Shaker Handle 24204 Ash Pan 68882 Ash Pan 1800 68919 Grate Retainer 40312 Grate Retainer 1800 40337 Shaker Bar 891341 Shaker Grate Section Shaker Grate Section 1800 N Kw NO NO N xN NO x NO Back Liner Back Liner 1800 Front Liner Front Liner 1800 18 Slide Baffle 24231 19 Baffle Rod 86603 ped Baffle Rod 1800 86607 20 Lock Nut 1 2 13 83444 Gasket Flue Collar 88032 22 40246 23 Flue Collar Ring 2276 ve Flue Collar Ring 1800 23958 24 23800 25 23787 26 Carriage Bolt 1 4 20 x 1 1 4 Long 83445 27 Kep Nut 1 4 20 83250 28 Cabinet Side Left 6882 Y Cabinet Side Front Left 1800 68962 2 Insulation Side C98771 Insulation Side 1800 23977 Insulation Retainer 83884 41 Cabinet Side Right 68822 Y Cabinet Side Right 1800 68961 N S Cabinet Side Back 1800 69002 32 80351 33 Cabinet Back 69573 w Cabinet Back 1800 69613 nsulation Panel C9887 1 nsulation Back 1800 23978 Insulation Top 1800 23979 Cabinet Top 69088 Cabinet Top 1800 68964 N i Flue Collar Smoke Curtain Smoke Door Clip 30 N Receptacle Snap In i N USSC 36 Front Filler 23817 YY Front Filler 1800 24190 1
3. iad iad j Model 16026 1802G Wood or Coal Gravity Style Up Flow Supplemental Furnace SAFETY NOTICE If this furnace is not properly installed a house fire may result For your safety follow these installation instructions Contact local building or fire officials about restrictions and installation requirements in your area This furnace must be installed by a qualified technician Keep these instructions for future reference safety Tested to UL 391 United States Stove Company 227 Industrial Park Road P O Box 151 South Pittsburg TN 37380 e www usstove com 851768 rev O INTRODUCTION Thank You for your purchase of a U S Stove Wood Coal Burning Gravity Style Up Flow Furnace Your decision to buy our Clayton Furnace was undoubtedly reached af ter much careful thought and consideration We are very proud you chose this furnace and trust you will receive the comfort and economy that others realize wnen heat ing with a U S Stove product Your dealer is important in your experience with the fur nace not only with the purchase but for recommen dations for professional installation in your home The qualified professional installer has been expertly trained in solid fuel furnace installation to assure the safety and comfort for your family while saving you money Trust your experienced installer He is a specialist in this field IMPORTANT Before installing and using your Clayton furnace please rea
4. 1 NOTE Never stand in front of loading door when opening it Stand to the side 2 NEVER completely cover the live fire with fresh coal Always leave a generous area of glowing coal at the top of the fire and at the rear 3 Always keep the ash pit clean J J J If the fire goes out or does not hold overnight look for 1 Poor draft Incorrect damper settings Improper firing methods for coal being used More combustion air needed O a WwW N Coal not sized to the furnace We recommend 1 to 3 diameter pieces of coal 6 Ashes if allowed to accumulate in the ash pit will not allow the passage of required air for combustion Keep ash pit clean 7 Thisfurnace isnot to be used with an automatic stoker unless so certified There are ONLY two types of coal allowed for use in this furnace Bituminous Coal soft coal and Anthracite Coal hard coal NEVER USE Cannel or Channel coal or Brown Lignite Coal see our Bulletin RC454 at the rear of this manual for the best information available on burning coal OPERATING NOTES Do not over draft the furnace It is designed to operate at 06 inches of water column and must be set with a draft gauge to maintain a steady draft Barometric Damper recommended Do not allow ashes to build up higher than 2 above grates Never allow the ashes in the ash pan touch the grate section REMOVE ASHES FREQUENTLY Be extremely careful wnen removing furnac
5. We NOT ROTATE HOLD i a A Ls NN O E O mim Honeywelt MR WALL THERMOSTAT 4 Spring Handles Oh OL O LIMIT INDICAT INDICATOR L 100 A n 200 SEE NOTE SECONDARY PRIMARY ROOM ROOM BLOWER BLOWER DISTRIBUTION BLOWER amp ACC 1 Remove all contents and insure that all components are present for assembly See the part list below 2 Begin by attaching the blowers to the unit Insert a clip into each mounting hole in the furnace s cabinet back Be sure to install the gasket between the blower and cabinet back Insert the eight bolts provided and tighten MANE BLACK BLACK 3 Mount the Honeywell limit control to the cabinet back The FAN CENTER conduit assembly should already be attached to the limit BLACK control otherwise do so then make the correct wiring con WHITE nections to the limit control See wiring diagram a ELECTRICAL A Next mount the junction box and insulation using two of the jir 10 x 1 2 screws provided Make a small slice in the 5 x 5 in GREEN NOTE PRIMARY ROOM BLOWER TO sulation to allow the wires from the draft blower to protrude ALL WIRING MUST BE DONE BE THE BLOWER ON THE LEFT FROM then Install it between the cabinet back and junction box POWER SUPPLY BY A QUALIFIED ELECTRICIAN REAR VIEW with the foil side to the cabinet back Attach the conduit assembly from the limit control to the junction box as shown 5 If not already ins
6. nected to the chimney impairing the draft J Check chimney draft it should be 06 inches of water column This service is provided by a certified chimney sweep Problem Inadequate heat being delivered to your home Solution A Check home insulation is it adequate B Check hook up to furnace is it installed correctly C Cool air inlet may be inadequate or furnace room too airtight D Your wood fuel may be too low grade Hardwoods are recommended E Make sure your hot air duct and other duct work is airtight F If furnace room is warm but your home isn t check back draft dampers G Is air to the blower available Problem Excess smoke or flames coming outdoor when refueling Solution A Wait 15 seconds and open door SLOWLY then refuel B Check length of flue pipe to chimney Your unit should be within six 6 feet of your chimney C Make sure chimney cap is not too close to the top of the chimney D Check chimney draft make sure chimney flue pipe is clean and chimney is of adequate height E Make sure you re not suffocating the fire with exces sive amounts of unburned wood F Slide baffle should be pulled out prior to load door opening USSC 4 Problem Distribution blower vibrating Solution A Tighten blower wheel to motor shaft B Check for bad fan bearings Problem Distribution blower continues to run or will not run Solution A Check fan limit or he
7. A common mistake is to assume that sheet metal masonry or millooard placed directly against a wall protects it Materials installed in this man ner actually provides very little protection These materials are good heat conductors so they will be almost as hot on their back side as they are on the exposed side There fore the combustible wall behind is still a fire hazard A wall can be kept cool using these items but only if they are mounted and spaced out from the wall by an inch or two to allow free air circulation behind the protective panel The protective panel should also have a gap be tween the floor and ceiling Three rules to follow when constructing wall protectors 1 Non combustibility of all materials including mount ing and supporting 2 A well ventilated air space between protector and wall 3 Sufficient strength and rigidity so that the protector and air soace will be durable PROTECTIVE COVERING AND ALL SUPPORTS MUST BE NON COMBUSTIBLE CONSTRUCTING NON COMBUSTIBLE WALLS 1 AIR SPACE u 2 FROM FLOOR gt USSC A fireclay lined masonry or Class A 103HT All Fuel Metal Insulated Chimney must be used in all airtight wood fur nace installations The minimum recommended flue size for the model 1602 is 6 inches inside diameter and for the 1802 the recommended flue size is 8 inches inside diam eter When making new chimney installations always fol low the chimney manufacturer s
8. as more soot will collect on heating surfaces and in pipes requiring more frequent cleaning ANTHRACITE Add a thin layer of coal preferably smaller chunks to the wood fire being careful not to disturb it too much or cut off the draft Then add a second heavier layer after the coal is ignited and burning well If necessary add a third layer to bring the coal up to the top of the front liner not above Be sure to close the ash door Before adding further fuel be sure to leave a red spot of glowing coals in the center of the firebox to insure that the fire has not been smothered and to help ignite the gases given off by the new charge A deep charge will give a more even heat and a longer fire but if may take one to two hours before the whole bed is fully ignited USSC BULLETIN RCAS4 A GUIDE TO BURNING COAL IN YOUR FURNACE When the fire is well established and the room is be coming warm partially close the dampers Some experimenting will have to take place with each particular setting of all dampers and controls as the chimney provides the draft necessary to not only exhaust the smoke but to pull combustion air into the heater as well and no two chimney s perform the same Under ideal draft conditions one should be able to turn the secondary air supply below the feed door some models to a near closed position but leave the ash pit damper at least partially open to prevent the fire from going out Adjust the sto
9. instructions If at all possible use the factory built class A 103HT chim ney mentioned above They are safer and perform better than traditional masonry chimneys If a masonry chimney is a must be certain it has a fire clay liner and that it is intact clean and recently inspected And remember masonry chimneys are far more prone to the formation of hazardous creosote TOP OF CHIMNEY MUST BE 2 FEET ABOVE HIGHEST POINT OF ROOF WITHIN 10 FEET KA 2 FT MINIMUM MINIMAL 3 FEET FROM TOP OF CHIMNEY TO POINT AT WHICH IT PASSES THROUGH THE CAP SHOULD HELP PREVENT DOWNDRAFT WHILE STILL PROVIDING ADEQUATE EXHAUST 3 FT MINIMUM RECOMMENDED MINIMAL 20 FEET CHIMNEY FLUE SHOULD BE A CONSTANT DIAMETER THROUGHOUT ITS ENTIRE HEIGHT CHIMNEY FLUE MUST BE AS LARGE OR 20 LARGER THAN THE FURNACE S FLUE APPROVED CHIMNEY CLEANOUT DOOR SHOULD HAVE AN AIR TIGHT FIT DO NOT LEAVE OPEN WHEN FURNACE IS IN OPERATION or Re iene pec ae RAL Bae eee Tod ert Be Peed bean ears CHIMNEY THIMBLE SHOULD BE CONSTRUCTED OF FIRE CLAY AND SHOULD FIT TIGHTLY TO FLUE PIPE 1 e furnace should be The only heating using the chimney flue One furnace per flue ouflet 2 Amasonry chimney should have a tile or stainless steel liner 3 The masonry chimney should not have any missing mortar or loose bricks A There should be no mortar or parts of the chimney blocking the chimney flue 5 There should be a two inch clearance betw
10. is attached The actual area that this unit will heat depends on factors such as the conditions of the building heat loss type of construction amount of insulation type of air movement the location of the unit and more importantly the duct work and return air facility Warning Do not alter this appliance in any way other than speci fied in these instructions Doing so may void your warranty LOCATING YOUR FURNACE The furnace is to be installed maintaining the clearances specified in the following illustrations Do not place the furnace directly on a combustible floor If you are placing it on a combustible floor an approved fire retardant material equivalent to 3 8 UL Listed mill board should be placed under the unit The material must extend at least 16 inches beyond the front of the unit and 8 inches on either side of the fuel loading door opening It must also extend underneath the chimney connector and to each side of the connector by at least 2 inches COMBUSTIBLE WALL Model Model 1602 20 1602 15 1802 25 1802 28 TOP VIEW Model MINIMUM CLEARANCES 1602 22 TO A COMBUSTIBLE 1802 19 WALL lt gt 2 gt fea O O CAUTION DO NOT store combustible or flammable materials or liquids near the furnace REDUCED CLEARANCES NFPA guidelines and most codes permit reduced clear ances to combustible walls and ceilings if adequate protection is added
11. of a Domestic Hot Water Coil Kit The U S Stove kit is a 1124 Water Coil and it may be purchased from your local dealer 1 Remove the access panel on the rear of the furnace enclosure 2 With a utility knife cut away a section of the insulation if equipped directly behind the access panel 3 Remove the cover plate from the rear of the furnace firebox 4 Place one nut on each end of the water coil and thread each nut up to the end of the threads on the Coll 5 Insert the coil through the holes from the inside of the firebox Install a gasket washer and nut onto each end of the water coil Tighten the nuts down securely to in sure an air tight seal The installation is now ready to be plumbed to your exist ing hot water system Choose one of the three methods described in the Hot Water Coil instructions 6 Remove knockouts from the access panel and re attach to the furnace enclosure Have a qualified plumber connect your domestic hot water pipe to the coil with the appropriate fittings DRG 6 DRAFT REGULATOR KIT OPTIONAL KIT In the unlikely event that your furnace overfires a con dition evidenced by elbows stove pipes and connec tors glowing red in appearance or otherwise discoloring then your installation is subject to excessive draft created by either a chimney too tall or too great in diameter in conjunction with its height or some other factor of an indeterminate cause In this event yo
12. shaker Rod into the bracket and attach to the shaker grate bar using the 1 4 20 x 1 Hex Bolt and a 1 4 20 Lock Nut The bolt and nut retaining the shaker bar and rod should be left loose to allow free movement of the grates 1 Shaker Rod 1 Shaker Bracket 1 1 4 20 x 1 Hex Bolt 2 1 4 20 x 3 4 Hex Bolt 3 1 4 20 Lock Nut I BRACKET AN Using two 1 4 20 x 1 1 4 Carriage bolts the smoke cur tain clips and two nuts attach the smoke curtain in place above the Fuel Feed Door as shown below After installa tion the smoke curtain should swing freely back into the furnace 1 Smoke Curtain 2 1 4 20 x 1 1 4 Carriage Bolt 1 4 20 NUT SMOKE CURTAIN CLIP 2 Smoke Curtain Clips 2 1 4 20 Kep Nut un 1 4 20 x 1 1 4 CARRIAGE BOLT ge SMOKE CURTAIN NUT N a BOLT dl SMOKE CURTAIN ___ A CLIP SMOKE CURTAIN a FRONT USSC SPRING HANDLES WIRING DIAGRAM Attach the four 4 spring handles to the Feed Ash Doors SETTING LIMIT CONTROL Baffle Rod and shaker Rod by twisting the springs counter oO Pt clockwise while applying pressure until you have screwed CAUTION TENE Honeywell them approximately 3 4 1 onto the rods
13. temperature falls to the first set point the distribution blower s will shut off The rocker switch on the top of the junction box gives you the op tion to run one blower or two If the switch is ON both blowers will come on when the plenum reaches the set temperature When the furnace reaches the third set point on the limit control the draft blower will shut off The draft blower will come back on if the temperature falls below the setting on the wall thermostat 1 Check the draft blower by turning the room thermostat up high enough so that the draft blower turns on Then lower the thermostat setting until you hear it shut off 2 Use a sheet of newspaper to test your draft by placing it inside the furnace and lighting it With completion of the tests above you are ready to light the furnace Follow the operating steps STARTING A WOOD FIRE Using Forced Air Draft CAUTION Never use gasoline gasoline type lantern fuel kerosene Charcoal lighter fluid or similar liquids to start or freshen up a fire in the furnace Keep all such liquids well away from the furnace while if is in use Open spin draft cap on ash door Pull the slide baffle rod to the front position Open the fuel load door and light fire using kindling and severalsheets of newspaper then close the furnace door The furnace door should remain closed for 5to 10 minutes in order to establish the fire If the fire has established you are re
14. 37 Draft Cover x Draft Cover 1800 38 39 4 42 43 45 47 48 49 50 N S Not Shown v Items designated for model 1800 IMPORTANT NOTE When ordering repair parts a color code G should be placed after the part number of any part that is painted 46 47 43 44 50 40 DD A iw y l SS FS 38 41 No h So e 13 PARTS DIAGRAMS AND LISTS 69189 UFB908 COLD AIR RETURN FILTER BOX OPTIONAL KIT As mentioned earlier in this manual a cold air return and Tr o IM SY S or filter box should be incorporated into your furnace in stallation A cold air return or filter box will increase the life of your blowers and offer filtered distribution air for your Unwed home U S Stove offers the model UFB908 as an option and can be purchased from your local dealer The UFB908 utilizes a standard 16 x 20 filter that can be purchased from your local dealer or any hardware duct work supply store When installing a UFB908 follow the in stallation instructions supplied with the kit N UDO QOOOOOO7T VV SOOOOOOOOOOOT iS 14 USSC DOMESTIC HOT WATER COIL KIT OPTIONAL REAR WALL OF FIREBOX DOMESTIC HOT WATER COIL 1 NUT Y a INSIDE NUTS UP 2 WASHER TO END OF THREADS 3 GASKET This Furnace will accept the installation
15. F degree chimney fire 1 The connector pipe should slant down toward the fur nace a minimum of 1 4 to the foot At no time should the pipe turn downward toward the chimney or run horizontal There should be no more than two 90 degree elbows The connector pipe should never be longer than six feet If it is absolutely necessary to make a run of more than six feet not recommended use extra support brackets every 3 feet 4 The connector pipe should never be reduced to a smaller size than flue opening on the furnace 5 The connector pipe should not block the flue of the chimney or extend into it in any way 6 Agood airtight thimble should be used to hold the con nector pipe in the chimney It should be constructed so the connector pipe can be removed for cleaning 7 The connector pipe should not leave the heated por tion of the building to reach the chimney 8 The connector pipe should not pass from one story to the next before entering the chimney nor should it pass through any closed or enclosed space 9 The connector pipe and any elbows must be of 24 gauge or greater 10 The connector pipe should not be located near or in a walk way or well traveled area 11 All male ends of connector pipe should run or point towards the furnace 12 Install a cast iron adjustable damper in the first joint of the connector pipe nearest to the flue collar DAMPERS ON STOVE PIPES When burning coal we recommend a Barom
16. LJ RETURN AIR IS VERY IMPORTANT When installing a Clayton Furnace return air MUST BE in corporated into the system Return air can be provided by installing a separate duct system or by tying into the cold air return of an existing gas or oil furnace The cold air return duct can be connected to the furnace with ei ther a factory manufactured U S Stove filter box model UFB908 or an equivalent fabricated from sheet metal When installing a cold air return the minimum size shall be a 16 x 20 or equivalent 320 sq in in order to insure proper furnace performance Failure to provide return air ducts of the specified size will void your warranty A filter should be installed in the cold air return Furnace fil ters should be checked and cleaned replaced regularly If return air is not provided the warm air distributed into your home will be restricted and the efficiency of the furnace is decreased Without a return air system warm air will be drawn into your basement unnecessarily heat ing unused areas of the home In extreme cases if your basement or utility room is fairly airtight the blowers on the furnace could depressurize the room and pull toxic flue gases from the furnace a gas water heater or gas furnace The fumes could then be distributed throughout the house USSC HOT AIR PLENUM EEE EXISTING CO FURNACE if used WOOD COAL FURNACE 9 FEET 1 MIN HOT AIR DUCT MINIMU
17. M CLEARANCES TO COMBUSTIBLES THE PLENUM OPENINGS DIFFER BETWEEN THE 1602 AND 1802 MODEL 1602 13 x 18 Rectangular MODEL 1802 18 x 18 Rectangular INCORRECT INSTALLATION Gl lt gt 1 he LZ Y Z NO RETURN AIR PROVIDED NEGATIVE PRESSURE IN BASEMENT Y Y y j 7 Z y Y 7 y Y N ara N COMBUSTION AIR All fires need air specifically oxygen to burn Furnaces fireplaces and wood burning furnaces need enough oxy gen for complete combustion of their fuels The incom plete combustion that takes place when a furnace is air starved causes carbon monoxide CO to be formed in quantities that can be dangerous inside a well sealed house Having a source of combustion air from outside the home will prevent air starvation of the furnace A simple positive air supply can be constructed using dryer vent and a modified termination 5 FURNACE ASSEMBLY INSTRUCTIONS Unpack your Furnace and insure that there is no shipping damage If damage exist please contact your dealer im mediately Your Clayton Furnace will require some assembly before operation All needed hardware and components for the following assemblies are included within the parts boxes inside the furnace and in the ash pan Read and follow these instructions for proper furnace assembly DOOR HANDLES Insert door hanale into door From rear side of door place a 1 2 washer over the threaded part of the handle then attach th
18. PTION MODEL NUMBER 1602 1802 SERIAL NUMBER United States Stove Company 227 Industrial Park Road P O Box 151 south Pittsburg IN 37380 423 837 2100 Customer Service 800 750 2723 Repair Parts 888 299 1440 20 USSC
19. ady to load the furnace N CAUTION To prevent flame and smoke spillage the slide baffle must be pulled out and the fuel doormust be cracked for fen seconds before being fully opened Do not over fire your furnace Affer you have become familiar with its operating you should know how much wood to use A Load the furnace close the load door and push the slide Baffle rod to rear 5 Close the spin draft cap on ash door leaving it cracked about the diameter of a dime USSC 6 The forced air draft cycles on demand from the wall thermostat Setting the U S Stove thermostat four degrees higher than your existing thermostat is recommended In operation the power draft blower will run until the U S stove thermostat temperature setting is reached The draft regulator on the forced air draft is preset at the factory and should require no adjustment CAUTION To avoid excessive temperatures do not operate with fuel door or ash pan open STARTING A COAL FIRE if you burn coal a forced air draft is required Shut off FAD when fuel door is open v Open smoke pipe damper all the way Open all draft controls on your 1602 1802 Pull the slide baffle forward v Place about 10 15 Ib of coal in on the shaker grates It should come up to about half of the first firebrick level v Place crumpled paper over the coal and crisscross a couple handfuls of dry kindling wood 3 4 in thickness on top of paper v Ignite the paper a
20. anding heater it is possible to achieve a reasonably safe and functional installation IE certain stan dard procedures are followed The following are guidelines only and are intended to enable the furnace user to obtain reasonable efficiency from his furnace and with due re spect to safety when installing as a free standing heater Ifinstalled correctly and in accordance with the instructions found in this manual your warm air furnace may be installed as a space heater within living quarters cabins garage or workshop Please adhere to the following 1 The use of a cold air return and or filter box is mandatory This will not only increase your blower life and provide filtered air it will also help prevent the blower or blowers from capturing heated air exiting from the top of the furnace heat outlets If installed as purchased without directing the heat away from the furnace itself it will simply sit and cycle turning the blowers off and on The thermostat may not function properly All larger furnaces or those with multi soeed blowers absolutely require BACK PRESSURE to prevent premature motor winding failure If allowed to operate at high RPM Asin FREE AIR mode no duct work or flow restrictions the windings overheat insulation melts and the motor simply burns up not covered under warranty CONNECTING HOT AIR DUCT TO FURNACE We strongly recommend that the hot air duct work be installed
21. arted with wood which will allow the fire to get hot enough to ignite the coal The best ignition fires utilize dry pine or other resinous soft woods as kindling with hard wood oak hicko ry ash added to increase the heat prior to addition of the coal Before starting the fire open the stove pipe damp er if epuipped turn the thermostat to high open the ash pit door and feed door place newspaper and finely split kindling on the grate light the paper add larger hard wood after the kindling is burning brightly CAUTION Never use gasoline lantern fuel kerosene charcoal lighter fluid or other flammable liquids to start or freshen up a fire in any heater Place the larger pieces of wood on the fire so that they are slightly separated and form a level for the addition of coal It will take 10 to 20 minutes before this wood is thoroughly ignited Adding coal too soon will cut the air supply and smother the fire BURNING BITUMINOUS Once your kindling and wocd fire has produced a bed of well established coals start adding coal in layers allowing each to ignite before adding more Bituminous has a high volatile content and as a re sult should be fired with the conical method with the highest portion of your fire bed in the center of the firebox The first flames will be long and generally 16 orange or yellow and produce quite a bit of smoke As the gases burn off the flames become shorter change color and produce l
22. at sensor and cable B Check to see that blower is properly wired See Wiring and Assembly Instructions C Check fuse box or power source D Check power supply Problem Draft blower continues to run or will not run Solution A Check wiring B Check thermostat or thermostat wire for short C Make sure temperature is calling for heat Problem Odor from first fire Solution A The odor from new steel should disappear in a few hours B If the odor remains call you dealer immediately A bad weld can cause a fume leak Problem Excessive Creosote Solution A Check the grade of wood you are burning B Make sure your unit is serviced by its own proper chimney C Check length of flue pipe and its connections D Make sure you are burning the smallest hottest fire to adequately heat your home E Also see Solutions to Problem one Problem If the fire goes out or does not hold over night Solution A Poor Draft B Incorrect damper settings C Improper firing methods if burning coal D More combustion air needed E Coal not sized to the furnace We recommend 1 to 3 diameter pieces of coal F Ashes if allowed to accumulate in the ash pit will not allow passage of the required air for combustion Keep ash pit clean G This furnace is not to be used with an automatic stoker unless so certified PARTS DIAGRAM O lh
23. by a home heating specialist If doing the instal lation yourself before you decide which installation will best suit your needs consult a qualified heating technician and follow his recommendations as to the safest and most efficient method of installation The following illustrations are the ONLY acceptable con figurations when installed with existing oil or gas furnaces INSTALLATION EXAMPLES INSTALLATION 1 With this installation a back draft damper optional is in serted into the heat run before the plenum of the existing furnace to prevent air from the existing furnace to blow back into the furnace when it is not in use When a back damper is employed it should be located as close to the existing furnace plenum as practical N Go BACK DRAFT DAMPER Q am u WOOD COAL EXISTING FURNACE FURNACE bg E USSC INSTALLATION 2 Extending the hot air duct from the furnace into the existing plenum will help direct the flow of air from the furnace as well as the flow in the existing furnace Ducting entering the existing plenum at an angle approximately 45 degrees will facilitate air flow from the furnace while diverting air from the existing furnace o WOOD COAL EXISTING FURNACE FURNACE LJ INSTALLATION 3 The baffle on this system should be made the full width of the furnace plenum in order to properly direct the air into the distribution ducts WOOD COAL EXISTING FURNACE FURNACE
24. d the following pages thoroughly and carefully If you follow the instructions your Clayton furnace will give you safe and more dependable service for years to come e First step Check your local codes This installation must comply with their rulings e Do Not install this furnace in a mobile home or trailer e Always have a smoke or ionization detector and a CO detector installed in your home e To prevent injury or damage do not allow anyone who is unfamiliar with the furnace to operate it This furnace must be installed ONLY in the prescribed manner shown in illustrations 1 2 or 3 under the In stallation Examples in this manual It is NEVER to be installed as a counter flow or down draft furnace or in any manner wherein the heated air is directed in a downward flow into the home or toward to an existing central furnace NEVER INSTALL outside the home e Soend adequate time with your furnace to become well acquainted with the different settings and how each will affect its burning patterns It is impossible to state just how each setting will affect your furnace be cause of the variations in each installation DISCLAIMER NOTICE The BIU ranges and heating capacity specifications are provided as a guide and in no way guarantee the output or capacity of this unit The actual BTU output depends on the type of fuel being burned and its conditions the thermostat setting the draft adjustment and the chimney to which the unit
25. e ash pan it can get very hot With new steel there is a small amount of oil or dirt on the metal You may smell an odor This is normal during the first operation You may want to assemble the furnace out of doors and build a small fire in it to burn off this dirt and oil before installing the unit The furnace is designed to burn air dried wood and coal at a predetermined firing rate Over firing could result in damage to the heat exchanger and cause danger ous operation Over firing occurs when the ash door is left open during operation or a highly volatile fuel i e large amounts of small kindling is used If any portion of the connector pipe glows orange or red you are in an over firing situation Close all dampers When tending the firebox always pull the baffle slide rod out prior fo opening load door Open load door slowly to avoid a flash back After closing load door push the baffle slide rod to the rear Equip your home with fire extinguishers and smoke de tectors appropriately located Inspect air filters regularly The air filter in the filter box should be changed at least every 30 days Oil motor on forced air draft every 90 days with a few drops of 30 wt oil The distribution blower motors may be one of two types If the motor has sealed bearings no oiling is required If the motor is equipped with fill holes the motor should be oiled every 90 days with several drops of 30 wt oil Check the f
26. e lock nut Tighten the nut then back off 1 4 turn to allow free operation of the handle Follow these same directions for the ash door handle as sembly U m 2 Door Handle u z 2 1 2 Washer f Of 2 1 2 Lock Nut N gt ASH DOOR SPIN DRAFT screw the spin draft onto the 3 8 x 2 1 2 carriage bolt Then screw the spin draft and bolt into the ash door al lowing approximately 1 2 of the bolt to stick through the back side of the ash door Secure the bolt in place with the 3 8 16 lock nut 1 Spin Draft 1 3 8 16 Carriage Bolt 1 3 8 16 Lock Nut FUEL amp ASH DOOR LATCH With two 1 4 20 x 3 4 hex bolts each attach the door latches to the door latch mounting brackets on the left side of the door frames as illustrated The slots in the brack ets and latches are for door seal adjustment Make the proper adjustments then tighten the nuts The door s gas ket should be snug against the door frame on the furnace Ash Door Illustration Feed Door 1 Feed Door Latch Illustration 1 Ash Door Latch 4 1 4 20 x 3 4 Hex Bolt 4 1 4 20 Kep Nut SHAKER GRATE HANDLE Insert the Shaker Rod into the hole on the ash door frame as shown Then attach the Shaker Bracket to the front of the furnace using two 1 4 20 x 3 4 Hex Bolts and two 1 4 20 Lock Nuts Next insert the
27. een any chimney masonry or metal and combustibles such as the house 6 The chimney should extend at least 2 foot above the highest point of the house or 2 foot above the point at which the chimney is 10 foot from the roof The chimney should be relatively straight and vertical The portion of an all fuel metal chimney that extends above the roof should be well secured 9 A masonry chimney should be built on footings and not attached to the house 10 A rain cap complete with an animal or bird screen should be installed on top of the chimney USE CREOSOTE FORMATION AND NEED FOR REMOVAL When wood is burned slowly it produces tar and other organic vapors which combine with expelled moisture to form creosote The creosote vapors condense in the rela tively cool chimney flue of a slow burning fire As a result creosote residue accumulates on the flue lining When ignited this creosote makes an extremely hot fire The chimney connector and chimney should be inspected at least twice monthly during the heating season to deter mine if a creosote build up has occurred If creosote has accumulated it should be removed to reduce the risk of a chimney fire SMOKE PIPE INSTALLATION Clearances to combustible materials i e paneling ceil ing tile sheet rock plaster draperies casements or wood trim etc will vary with the type of flue connection used Be sure to maintain the specified clearances for your type of in
28. en allowing the opposite end to rest on the firebox lip Lay the brick between the spacer and firebox back Slide the baffle to the rear and let it rest on that half brick After installing brick 2 in the front install 43 and slide it under the baffle Finally install bricks 4 and 5 For model 1802 there are 6 full brick in the top of the fur nace Install the brick in the same manner as previously instructed above ACCESS BAFFLE NUTS THRU THE FLUE OPENING BRICK SPACERS FOR ILLUSTRATION PURPOSES ONLY FOR CLARITY CABINET SIDE AND TOP REMOVED FIREBOX TOP IS SHOWN AS SEE THRU USSC TESTING AND OPERATING PROCEDURES GENERAL FURNACE OPERATION After installation of the furnace is complete it is ready for operation The Honeywell Limit Control in conjunction with a wall thermostat operates the distribution blowers and the draft blower on the front of the furnace The limit control can be adjusted to your desired blower On Off times The factory settings are 100 150 200 The wall thermostat setting operates the ON time of the draft blower If the temperature is below the setting on the wall thermostat the draft blower will come on Rec ommended setting at 5 to 10 degrees higher than other heating thermostats The first two set points on the limit control operates the distribution blower s When the furnace plenum reaches the second set point on the limit control the distribution blower s will come on If the
29. ess smoke Once the fire is WELL ESTABLISHED add coal to the center of the firebox forming the cone Burning in this fashion allows heat to drive off the volatile gases and turbulence created increases the burn efficien cy There will have to be some experimenting with the individual setup as no two chimney s or instal lations are going to be the same Just remember to allow enough air to enter the firebox and keep the stove pipe damper open so that volatiles are prop erly burned Before refueling take the time to break up the cone a little with a poker especially if it has caked over or formed a crust But be careful not to mix the coal as this increases the chances of form ing clinkers When shaking the grate s be gentle Just a few short movements a couple of cranks is better than a lot of agitation The objective is to remove a small amount of the ashes without disturb ing the fire Stop when you see a glow in the ashes or the first red coals fall into the ash pan Excessive shaking wastes fuel and can expose the grate s to very high temperatures which can cause warpage or burnout For overnight operation long duration burn time shake the fire and add coal retaining the center cone Once the volatiles are burned off close the feed door and adjust the stove pipe damper if epuipped Then adjust the thermostat to the desired heat level More MAINTENANCE will be needed with bituminous coal than with anthracite coal
30. etric Draft Damper be installed at a safe convenient place between chimney and your furnace preferably less than 3 from the flue collar When you have installed the connector pipe between your furnace and the chimney tap the pipe hard with your fingernail Remember the sound it makes it will be a ting echoing inside the stove pipe If later you tap and hear a muffled thud you are building up soot in the pipe and should clean it This pipe should be cleaned at least once or twice during the heating season DO NOT CONNECT TWO HEATERS TO THE SAME CHIMNEY FLUE The National Fire Prevention Association recommends that wood burning appliances vent into aseparate flue from gas or oil furnaces If such an installation is contemplated first check with a local building inspector to find out if a separate flue for a wood burner is required Use of a Barometric Draft Control when burning wood is recommended ONLY in the event your chimney creates excessive draft leading to an over firing condition HEATED AIR DISCHARGE The Clayton furnace is designed for use as a supplemental heating source When used as a supplementary furnace the 1602 1802 is connected in conjunction with an oil gas or electric furnace to the existing duct work which distributes the heated air into several rooms and or areas 4 EN 1 Though United States Stove Company expressly Does Not recommend the use of its furnaces to be installed and or used as a free st
31. it on the load door It must fit tightly If it does not check for deterioration or wear of the ceramic rope seal Replace defective seals J Insoect and clean your chimney and stove pipe regularly In event of chimney fire shut all draft controls and call your fire department immediately Alert everyone in the house If the fire is still burning vigorously throw baking soda into firebox or discharge a fire extinguisher into the firebox After chimney fire is over completely inspect system for damage before further use NEVER throw water on the fire or at the furnace as rapidly expanding steam could result in a severe scalding Slow fires It is not recommended burning the Clayton furnace any more than necessary early in the fall and late spring as you cannot keep the firebox hot enough without overheating your home to burn gases Slow fires can cause excessive creosote build up in smoke pipe chimney and firebox Wood should be placed directly onto the cast iron shaker grate of the Clayton furnace Do not use additional grates and or irons In the event of a power failure you may operate the 1602 1802 furnace provided the following instructions are followed 1 Any air filter should be removed 2 Observe the furnace operation closely and often till power is restored Do not burn garbage plastics gasoline drain oil or other flammable liquids Plastics wnen burned form hydrofluoric and hydrochloric acids which wi
32. ll dam age and destroy your furnace pipe and chimney The burning of trash or oil can result in an extremely hot fire and is sometimes a cause of chimney fires NEVER BURN GREEN WOOD OR TIRES Do not store fuel or other combustible material within marked installation clearances NOTE For further information on using your furnace safely obtain a copy of the National Fire Protection Association publication Using Coal and Wood Stoves Safely NFPA NO NW 8 1974 The address of the NFPA is 470 Atlantic Ave Boston Massachusetts 02210 THIS IS A WOOD AND COAL BURN ING FURNAGE AND SHOULD NOT BE ALTERED IN ANY WAY DOING SO WILL VOID YOUR WARRANTY USSC TROUBLE SHOOTING AND PROBLEM SOLVING 1 Problem Smoke puffs from furnace Solution A Check chimney draft Check for blocked chimney or flue pipe Use mirror to check chimney clearance B Check ash pit if it is too full empty Make sure furnace room is not too airtight D Make sure all of chimney mortar connections are airtight Check ash drawer Make sure it s airtight F Check chimney for possible down draft caused by taller surrounding trees or objects Correct with proper chimney vent cap G Check the possibility of a cold chimney forcing coo gases backward Remedied by properly insulating chimney with non combustible liner non combus tible insulation H Fuel may be too green Make sure no other fuel burning devices are con
33. nd close loading door Wait about 30 minutes until coal fire is established before adding more coal NOTE NEVER load coal over the level of firebrick v Close by pass damper and set all draft controls to your own needs lt may take 3 to A coal fires to determine how your local coal and the Clayton Furnace reacts together Adjusts drafts accordingly Y Loading with a good bed of coals in the morning Open by pass damper 1 Innormalshaking only rock the grates a small amount to siff ash through Do not agitate the fire bed too often This practice will waste coal If glowing coal is visible in the ash pan you have shaken to much 2 Remove all ashes every day from ash pit CAUTION Ashes should be placed in ametal container with a fight fitting lid The closed container of ashes should be placed on a non combustible fioor or on the ground well away from all combustible materials pending final disposal If the ashes are disposed of by burial in soil or otherwise locally dispersed they should be retained in the closed container until all coals have thoroughly cooled 3 With your poker push hot burning embers to the rear of the unit and add green coal in front NEVER load over height of firebrick This can result in damage to your furnace and home 4 Close by pass damper v Too much craft air will cause clinkering of coal and will waste heat up the chimney Shut draft down to as low a point as you can and still heat your home
34. stallation TYPE OF FLUE REQUIRED CONNECTION CLEARANCE 24 GAUGE Or Heavier esre 18 single Wall Stainless Steel or Black Pipe Double Wall Stainless Steel Of 6 Model 1602 Double Wall Black Pipe w 8 Model 1802 Stainless Steel Inner wall Class A 103HT All Fuel or Equivalent 2 77 MBUS TIPLE 7 SMOKE PIPE According to NFPA standards single wall stove pipes can be within 9 of combustibles provided an approved fire retardant material covered with 28 gauge sheet metal soaced out 1 on non combustible spacers is utilized See illustration CEILING OR WALL When using a Class A or double wall flue pipe connection follow the manufacturer s instructions When constructing a single wall smoke pipe the following guidelines must be observed 1 The connector pipe should be 24 gauge or heavier stainless steel or black pipe 2 Secure all joints with three 8 screws 3 If fhe connector pipe must pass through a wall an ap proved insulated or ventilated thimble at least three times the diameter of the smoke pipe must be used i e a 6 diameter smoke pipe needs an 18 thimble A The connector pipe should never be used as a chimney 3 IMPORTANT INFORMATION FOR ALL CONNECTOR PIPES The connector pipe must be constructed and installed so that it maintains clearances keeps condensation and creosote within the pipe and is capable of withstanding a 2100
35. talled snap the rocker switch into the top of the junction box Provide a 110 volt power supply and con nect to the junction box with the cable clamp to the right side Attach the two longer conduit assemblies to the junction box and to each blower 7 Before mounting the Fan Center make all the wire connec tions per the wiring diagram then attach the fan center to the junction box All electrical connections should be done by a qualified electrician NOTE The extra brown wire on the fan center has no use It should be capped off or removed The conduit may be cut shorter to provide a cleaner installation 2 800 CFM Blower 2 Gasket Blower 8 Tinnerman Clip 1 4 20 8 1 4 20 x 3 4 Bolt 2 Conduit Assembly ft 1 Honeywell Limit Control 1 Conduit Assembly 1 ff 1 Junction Box 1 Insulation 8 x 5 1 Rocker Switch 1 Romex Cable Clamp 1 Fan Center Control 3 73B Wire Nut 1 74B Wire Nut 1 Female Term blue 1 Female Term red 8 10x 1 2 Screw USSC o FORCED DRAFT BLOWER 69189 Using two 1 4 20 x 1 bolts and nuts attach the draft blow er adapter to the draft tube on the front of the furnace Then mount and secure the draft blower to the adapter with the three 10 24 Kep nuts Plug the blower into the out let on the front of the furnace 1 Draft Blower 1 Draft Blower Adapter 2 1 4 20 x 1 Hex Bolt 2 1 4 20 Lock Nut 3 10 24 Kep Nut
36. u should install a barometric draft regulator Such installation will preclude any over firing and or any hazardous consequences of potential overfiring Barometric draft regulators are generally available where you purchased your stove or may be ordered directly from United States Stove Company at a nominal charge USSC BULLETIN RC454 A GUIDE TO BURNING COAL IN YOUR FURNACE Furnaces that are capable of burning coal usually will burn both Bituminous and Anthracite coal An thracite is perhaps the best coal fuel because of its long even burn time high heat output and cleanli ness which make it a good choice for the home However keep in mind if is a much more difficult fuel to use requires More care and patience is not so widely available and is usually much more ex pensive than Bituminous SIZE OF COAL Most sizes of Bituminous Coal will work in a coal fur nace for best results we recommend large nut coal to small egg coal 1 3 4 diameter to 4 di ameter When burning Anthracite use egg or broken with sizes between 2 5 16 thru 4 3 8 Note that it is important to the long life of your stove to buy coal which has been sized and cleaned Cleaning insures removal of rocks and other miner als Never use coal smaller than 1 or larger than 5 in diameter Small sized coal will smother the fire Too large a size of coal will not burn well STOVE OPERATION All coal fires should be st
37. ve pipe damper to reduce the draft on the fire With anthracite there will be short blue flames above the coal except when the fire is started or a new charge is added If however there is no flame then the fire needs more air from the bottom unless it is near the end of its burn cycle and needs to be re charged Only when the coal is burned down to half its origi nal depth it is time to add fresh coal When doing so open the stove pipe damper and turn the thermo stat damper to high which will allow the fire to burn off any accumulated gases Open the feed door and with a small rake hoe or hooked poker pull the glowing coals to the front of the firebox Try not to disturb the fire too much Next add a fresh charge to the back being careful not to seal off the top Close the feed door but leave the spin damper or thermostat open for a few minutes until the volatile gases have burned off It is not necessary to shake down the ashes each time you refuel the furnace Experience will be your best teacher USSC BANKING THE FIRE For extended operation such as overnight the fire will need to be banked To do so heap coal up along the sides and back of the firebox so that the fire gradually burns it over a longer period of time The intensity of the fire will also be reduced without letting it go out Follow the same procedure as for refueling If possible avoid shaking as a heavier layer of ash will helo reduce the intensit
38. y of the fire during this time After loading let the fire establish itself for about 30 minutes Then close your damper and automatic control to the point where the house does not become too cold It is important that you begin banking early enough before retiring or leav ing that you can make necessary adjustments after the fire is well established To revive a coal fire that is almost out 1 open the ash door and stove pipe damper and close the spin damper under the door to get a good draft through the grate 2 place a thin layer of dry coal over the entire top of the fire DO NOT POKE OR SHAKE THE FIRE AT THIS TIME 3 after the fresh coal has become well ignited shake the grate just a little refuel DO NOT burn coke charcoal high volatile bitumi nous coal sub bituminous lignite or cannel coal sometimes called channel coal or candle coal NEVER burn wax or chemically impregnated saw dust logs their intended use is for fireplaces only NEVER fill the stove or furnace above the firebrick or cast iron liner 18 USSC USSC HOW TO ORDER REPAIR PARTS This manual will help you obtain efficient dependable service from the fur nace and enable you To order repair parts correctly Keep this manual in a safe place for future reference When placing an order or for warranty claims please provide the following information found on the Certification Plate located below the ash door PART NUMBER PART DESCRI
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